BACKGROUND
[0001] The present disclosure relates to a post-processing apparatus for performing a given
process subsequently to an image forming process by an image forming apparatus.
[0002] Known image forming apparatuses are configured to incorporate a blower into an ejection
mechanism for ejecting a sheet. One of the known image forming apparatuses forms airflow
on an upper surface of a sheet to stabilize an ejection of the sheet, the airflow
flowing in an ejection direction of the sheet. Another of the known image forming
apparatuses blows air between two sheets, which are sequentially sent, to reduce friction
between the sheets.
[0003] With regard to a post-processing apparatus for performing a given process subsequently
to an image forming process by an image forming apparatus, sheets are stacked on one
tray to form a stack of the sheets (sheet stack). When sheets are sent sequentially,
sheets which have already stacked on the tray may be pushed in the ejection direction
by a subsequent sheet. If the aforementioned conventional techniques are applied to
the post-processing apparatus, air from a blower works in the ejection direction to
push the sheets which have already stacked on the tray. Therefore, the aforementioned
conventional techniques are not suitable to application to an ejection mechanism of
the post-processing apparatus.
[0004] In addition, a frictional force caused between the sheets depends on a material of
sheets and/or a condition of an image formed on the sheets. When the frictional force
caused between the sheets is very large, the friction reduction effect using airflow
may be insufficient. Therefore, even if a blower is placed so that air does not hit
sheets which have already stacked on the tray, the sheets on the tray may be pushed
by a subsequent sheet.
SUMMARY
[0005] A post-processing apparatus of the present disclosure is designed to perform a given
process subsequently to an image forming process by an image forming apparatus. The
post-processing apparatus includes: a first ejector which ejects a first sheet; a
first tray which temporarily holds the first sheet ejected by the first ejector; a
second tray situated downstream of the first tray in an ejection direction of the
first sheet; a tray driver which moves the second tray downwardly from a first height
position; a first blower which forms an airstream between the second tray and a lower
surface of the first sheet when the first sheet is ejected by the first ejector; and
a controller which controls the first blower and the tray driver. The controller includes:
(i) a first blower controller which causes the first blower to blow air over a time
period in synchronization with a first time period from a start to an end of an ejection
of the first sheet by the first ejector; and (ii) a tray controller which causes the
tray driver to move the second tray downwardly from the first height position after
the first time period.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006]
FIG. 1 is a schematic sectional view of a part of an exemplary post-processing apparatus
which is used together with an image forming apparatus for forming an image.
FIG. 2 is another schematic sectional view of the post-processing apparatus.
FIG. 3 is a conceptual view of operations of a first blower and a second blower of
the post-processing apparatus.
FIG. 4 is a schematic block diagram showing an exemplary functional configuration
of a controller for controlling various operations of the post-processing apparatus.
FIG. 5 is a schematic timing chart of a detection signal output from a sheet detector
of the post-processing apparatus shown in FIG. 1.
FIG. 6 is a schematic flowchart showing an operation of a determination portion of
the controller.
FIG. 7 is a schematic flowchart showing an operation of a drive controller of the
controller.
FIG. 8 is a schematic flowchart showing an operation of a displacement controller
of the controller.
FIG. 9 is a schematic flowchart showing an operation of a pulling-back controller
of the controller.
FIG. 10 is a schematic flowchart showing an operation of a blower controller of the
controller.
FIG. 11 is a schematic flowchart showing processes which are executed by the determination
portion of a counter of the controller.
FIG. 12 is a schematic flowchart showing processes which are executed by a first blower
controller of the blower controller.
FIG. 13 is a schematic flowchart showing an exemplary process, which is executed by
the blower controller to determine whether air should be blown or not.
FIG. 14 is a schematic block diagram showing an exemplary functional configuration
of the post-processing apparatus.
FIG. 15 is a schematic flowchart showing an exemplary process which is executed by
a tray controller of the post-processing apparatus.
FIG. 16 is a schematic flowchart showing an operation of the tray controller.
FIG. 17 is a schematic plan view of a first tray of the post-processing apparatus.
FIG. 18 is a schematic flowchart showing an exemplary process which is executed by
a pulling-back controller.
FIG. 19 is a schematic block diagram showing an exemplary functional configuration
to make an aligning operation of an alignment portion in collaboration with a pulling-back
operation of a pulling-back mechanism of the post-processing apparatus.
FIG. 20 is a timing chart of detection signals from a first detector and a second
detector, a drive signal output from the tray controller to a tray driver, a stop
trigger output to the tray controller and an alignment control signal.
DETAILED DESCRIPTION
< Schematic Structure and Operation of Post-processing Apparatus >
[0007] FIGS. 1 and 2 are schematic sectional views of a part of an exemplary post-processing
apparatus 100 which is used together with an image forming apparatus (not shown) configured
to form images. A schematic structure of the post-processing apparatus 100 is described
with reference to FIGS. 1 and 2. The arrowed dotted line shown in FIG. 1 conceptually
indicates a flow of a sheet in the post-processing apparatus 100. In the following
description, the direction indicated by the arrowed dotted line is referred to as
"ejection direction". The direction opposite to the ejection direction is referred
to as "pulling-back direction".
[0008] The image forming apparatus forms an image on a sheet (image forming process). The
sheet is then conveyed from the image forming apparatus to the post-processing apparatus
100. The post-processing apparatus 100 subjects the sheet to formation of a through-hole,
stapling and/or folding. The principle of this embodiment is not limited by specific
processes performed by the post-processing apparatus 100.
[0009] The post-processing apparatus 100 includes a part for conveying sheets, a part for
supporting the conveyed sheets, a part for reducing friction which acts on the sheets
under conveyance, and a part for performing a post-process. These parts are described
below.
[0010] As the part for conveying sheets, the post-processing apparatus 100 is equipped with
a first ejector 210, a second ejector 220 and a pulling-back mechanism 500. The first
and second ejectors 210, 220 are situated on a sheet conveyance path. The first ejector
210 sends a sheet in the ejection direction. The second ejector 220 is situated downstream
of the first ejector 210 in the ejection direction, and conveys a sheet in both of
the ejection direction and the pulling-back direction. The pulling-back mechanism
500 is situated between the second and first ejectors 220, 210, and conveys a sheet
in the pulling-back direction.
[0011] As the part for supporting sheets conveyed by the first and second ejectors 210,
220 and the pulling-back mechanism 500, the post-processing apparatus 100 is equipped
with a first tray 310 situated beneath the sheet conveyance path extending from the
first ejector 210 toward the second ejector 220, and a second tray 320 situated downstream
of the first tray 310 in the ejection direction. The first tray 310 supports sheets
conveyed in the pulling-back direction by the second ejector 200 and the pulling-back
mechanism 500. The second ejector 200 and the pulling-back mechanism 500 sequentially
send sheets in the pulling-back direction, so that the sheets are stacked on the first
tray 310 to form a sheet stack on the first tray 310. The sheet stack on the first
tray 310 is sent in the ejection direction by the second ejector 200, and supported
by the second tray 320.
[0012] In order to reduce friction which acts on a part of a sheet appearing on the second
tray 320, the post-processing apparatus 100 forms an airflow along a surface of the
second tray 320, and/or causes the part of the sheet appearing over the second tray
320 to be curved downwardly and reduce a contact area with a subsequent sheet. The
post-processing apparatus 100 is equipped with a first blower 410 for forming the
airflow along the surface of the second tray 320, and a second blower 420 for causing
the part of the sheet appearing over the second tray 320 to be curved downwardly.
The first blower 410 is situated beneath the first tray 310, and blows air upwardly.
The air which is blown upwardly forms airflow along the surface of the second tray
320. The second blower 420 is situated just above the second tray 320, and blows air
toward the second tray 320. The air from the second blower 420 hits the upper surface
of a part of the sheet appearing over the second tray 320, so that the air causes
the part of the sheet to be curved downwardly.
[0013] Before sending the sheet stack to the second tray 320, the post-processing apparatus
100 performs a post-process for bundling the sheets on the first tray 310. The post-processing
apparatus 100 is equipped with a stapler 110 for bundling sheets. The stapler 110
is situated upstream of the first tray 310 in the ejection direction.
[0014] The first ejector 210 just above the first tray 310 includes two rollers 211, 212.
The roller 212 is situated above the roller 211. The rollers 211, 212 nips a sheet
which arrives at the first ejector 210 via a sheet conveyance path (not shown) formed
inside the post-processing apparatus 100. The roller 212 is driven by a motor (not
shown). When the roller 212 is rotated by the motor, the sheet is moved in the ejection
direction. The roller 211 is rotated by the movement of the sheet in the ejection
direction.
[0015] The sheet sent in the ejection direction by the rollers 211, 212 reaches the second
ejector 220. The second ejector 220 includes two rollers 221, 222. The roller 222
is situated above the roller 221. The roller 221 is driven by a motor (not shown).
The roller 222 is displaced between an adjacent position adjacent to the roller 221,
and a distant position distant from the roller 221 (the position shown in FIGS. 1
and 2). A variety of known mechanisms for displacing a position of a roller may be
applied to a displacement mechanism for displacing the roller 222 between the adjacent
position and the distant position. The principle of the present embodiment is not
limited to a specific mechanism for displacing the roller 222 between the adjacent
position and the distant position.
[0016] The roller 222 is placed at the adjacent position in order to convey a sheet (hereinafter
referred to as "first sheet"), which the first ejector 210 initially supplies from
the image forming apparatus to the post-processing apparatus 100. The first sheet
is nipped between the rollers 221 and the roller 222 situated at the adjacent position,
and conveyed in the ejection direction and the pulling-back direction. The roller
222 is placed at the distant position when at least one sheet (hereinafter referred
to as "subsequent sheet") is sent from the first ejector 210 toward the second ejector
220 subsequently to the first sheet. The subsequent sheet is allowed to pass through
a gap between the rollers 221, 222, so that the first ejector 210 may convey the subsequent
sheet in the ejection direction without interference with the second ejector 220.
When the subsequent sheet is ejected from the first ejector 210, the pulling-back
mechanism 500 sends the subsequent sheet in the pulling-back direction.
[0017] The pulling-back mechanism 500 includes a rotary shaft 510 shaped as a round bar,
and a paddle arm 520 extending in a tangent direction to a circumferential surface
of the rotary shaft 510. The rotary shaft 510 is rotated by a motor (not shown) when
the first ejector 210 completes the ejection of the subsequent sheet. When the rotary
shaft 510 is rotated, the paddle arm 520 is brought into contact with an upper surface
of the subsequent sheet, and elastically bent. By a frictional force between the paddle
arm 520 and the upper surface of the subsequent sheet ejected from the first ejector
210, and a restoring force caused by the elastic deformation of the paddle arm 520,
the subsequent sheet is moved in the pulling-back direction and placed on the first
tray 310. Accordingly, the subsequent sheet is stacked on the first sheet to form
a sheet stack on the first tray 310. The first tray 310 temporarily holds the sheet
stack.
[0018] The sheet stack formed on the first tray 310 is stapled by the stapler 110, so that
sheets of the sheet stack are bundled. The stapler 110 may have the same structure
as that of a stapler incorporated into a known post-processing apparatus. The principle
of the present embodiment is not limited to a specific structure of the stapler 110.
[0019] The first tray 310 situated next to the stapler 110 includes a proximal end 316 situated
beneath the first ejector 210, and a distal end 317 to which the roller 221 of the
second ejector 220 is attached. The proximal end 316 is situated at a height position
lower than the distal end 317. Consequently, the first tray 310 forms a support surface
318 extending obliquely upwardly from the proximal end 316 toward the distal end 317.
The sheet stack is supported on the support surface 318 of the first tray 310.
[0020] The second tray 320 situated downstream of the first tray 310 extends in the ejection
direction from a region beneath the second ejector 220. The second tray 320 includes
a proximal end 321 situated beneath the roller 221 of the second ejector 220, and
a distal end 322 away from the proximal end 321 in the ejection direction. The distal
end 322 is situated above the proximal end 316. Consequently, the second tray 320
forms a support surface 323 extending obliquely between the proximal end 321 and the
distal end 322. The support surface 323 of the second tray 320 supports a part of
the sheet stack which protrudes from the first tray 310.
[0021] Each of the first and second blowers 410, 420 blows air to a space above the second
tray 320. Airflows from the first and second blowers 410, 420 are conceptually indicated
by the arrowed solid lines in FIG. 1, respectively. The direction of the airflow from
the second blower 420 is substantially perpendicular to the support surface 323 of
the second tray 320 whereas the air from the first blower 410 is blown through a gap
between the proximal end 321 of the second tray 320 and the roller 221 of the second
ejector 220 to form an airflow substantially in parallel to the support surface 323
of the second tray 320. A general fan device may be used as each of the first and
second blowers 410, 420. For example, an axial flow fan, a centrifugal fan, a diagonal
flow fan or a cross flow fan may be used as each of the first and second blowers 410,
420. The principle of the present embodiment is not limited to a specific blower used
as each of the first and second blowers 410, 420.
[0022] A schematic sheet conveyance operation of the post-processing apparatus 100 is described
below.
[0023] The first sheet and the subsequent sheet are sequentially sent from the image forming
apparatus to the post-processing apparatus 100. Accordingly, the first ejector 210
sequentially receives the first sheet and the subsequent sheet. The rollers 211, 212
of the first ejector 210 nip the first sheet and the subsequent sheet, and sequentially
send them in the ejection direction.
[0024] When the first ejector 210 ejects the first sheet, the roller 222 of the second ejector
220 is placed at the adjacent position. Therefore, the first sheet is nipped between
the rollers 221, 222. During a time period from a start to an end of the ejection
of the first sheet from the first ejector 210, the roller 221 is rotated by the motor
(not shown) so that the first sheet is sent in the ejection direction. Meanwhile,
the roller 221 is rotated by the movement of the first sheet in the ejection direction.
When the first ejector 210 completes the ejection of the first sheet, the roller 222
is rotated by the motor so that the first sheet is sent in the pulling-back direction.
Meanwhile, the roller 222 is rotated by the movement of the first sheet in the pulling-back
direction. As a result of conveyance of the first sheet in the pulling-back direction,
the first sheet is supplied onto the first tray 310. At this moment, a part of the
first sheet protrudes from the first tray 310 in the ejection direction and is supported
by the second tray 320.
[0025] When the first ejector 210 ejects the subsequent sheet subsequently to the first
sheet, the roller 222 of the second ejector 220 is placed at the distant position.
Instead of the second ejector 220, the pulling-back mechanism 500 conveys the subsequent
sheet in the pulling-back direction after the subsequent sheet has been ejected from
the first ejector 210.
[0026] When the first ejector 210 completes the ejection of the subsequent sheet, the rotary
shaft 510 of the pulling-back mechanism 500 is rotated by a motor (not shown). Upon
the rotation of the rotary shaft 510, the paddle arm 520 is brought into contact with
an upper surface of the subsequent sheet and elastically bent. By a frictional force
between the paddle arm 520 and the upper surface of the subsequent sheet ejected from
the first ejector 210, and a restoring force caused by the elastic deformation of
the paddle arm 520, the subsequent sheet is moved in the pulling-back direction and
placed on the first tray 310. Consequently, the subsequent sheet is stacked on the
first sheet to form a sheet stack on the first tray 310. The sheet stack is then stapled
by the stapler 110, so that the sheets in the sheet stack are bundled.
[0027] After stapler 110 stapes the sheet stack, the roller 222 of the second ejector 220
is displaced downwardly. Consequently, the sheet stack is nipped between the rollers
221, 222. Subsequently, the roller 221 is rotated by the motor so that the sheet stack
is conveyed in the ejection direction. As a result of the rotation of the roller 221,
the sheet stack is ejected from the first tray 310 to the second tray 320.
[0028] Schematic air-blowing operations of the first and second blowers 410, 420 of the
post-processing apparatus 100 are described below.
[0029] The first blower 410 blows air from an outlet formed between the roller 221 of the
second ejector 220 and the proximal end 321 of the second tray 320 when the first
ejector 210 sends the first sheet in the ejection direction. Accordingly, airflow
is formed between the lower surface of the first sheet and the support surface 323
of the second tray 320. Since the airflow significantly reduces a frictional force
between the first sheet and the support surface 323 of the second tray 320, the first
sheet may smoothly move in the ejection direction.
[0030] In synchronization with the start of the air-blow from the first blower 410, the
second blower 420 situated just above the second tray 320 also blows air to the support
surface 323 of the second tray 320 in a direction substantially perpendicular to the
support surface 323. Accordingly, the air blown downwardly from the second blower
420 is hit against the upper surface of the first sheet.
[0031] When the first sheet is conveyed in the pulling-back direction or when the first
sheet is received in the first tray 310, the first blower 410 stops blowing the air.
On the other hand, the second blower 420 continues the air-blow. Accordingly, the
first sheet protruding is curved downwardly above the support surface 323. The downward
curvature of the first sheet protruding above the support surface 323 means that the
first sheet moves away downwardly from a conveyance path of the subsequent sheet.
Therefore, there is a significant reduction in contact area between the first sheet
and the subsequent sheet. Accordingly, the subsequent sheet is less likely to come
into close contact with the first sheet.
[0032] While the subsequent sheet is conveyed in the ejection direction by the first ejector
210 and while the subsequent sheet is conveyed in the pulling-back direction by the
pulling-back mechanism 500, air is blown from the second blower 420 to the upper surface
of the subsequent sheet. A volume (volumetric flow rate) of the air from the second
blower 420 is set to be less than the volume (volumetric flow rate) of the air from
the first blower 410. Therefore, the air blown from the second blower 420 does not
excessively strongly press the subsequent sheet against the first sheet. In short,
the air-blow from the second blower 420 does not cause a close contact between the
subsequent sheet and the first sheet.
[0033] FIG. 3 is a conceptual view of operations of the first and second blowers 410, 420.
The operations of the first and second blowers 410, 420 are further described with
reference to FIGS. 1 to 3.
[0034] FIG. 3 conceptually shows a first time period and a second time period. The first
time period means a time period between a time when the first ejector 210 starts ejecting
the first sheet and a time when the first ejector 210 completes the ejection of the
first sheet. The second time period means a time period between a time when the pulling-back
mechanism 500 starts conveying the subsequent sheet, which is ejected next to the
first sheet, in the pulling-back direction and a time when the pulling-back mechanism
500 completes the conveyance of the subsequent sheet in the pulling-back direction.
[0035] During the first time period, the first blower 410 is operated so that air is blown
from the first blower 410. The air-blow from the first blower 410 may be started in
synchronization with the start of the first time period. Alternatively, the air-blow
from the first blower 410 may be started before the start of the first time period.
Alternatively, the air-blow from the first blower 410 may be started between the start
and the end of the first time period. The air-blow from the first blower 410 may be
completed in synchronization with the end of the first time period. Alternatively,
the air-blow from the first blower 410 may be completed before the end of the first
time period. Alternatively, the air-blow from the first blower 410 may be completed
between the end of the first time period and the start of the second time period.
[0036] Like the first blower 410, the second blower 420 is operated during the first time
period so that air is blown from the second blower 420. The air-blow from the second
blower 420 may be started in synchronization with the start of the first time period.
Alternatively, the air-blow from the second blower 420 may be started before the start
of the first time period. Alternatively, the air-blow from the second blower 420 may
be started between the start and the end of the first time period.
< Controller of Post-processing Apparatus >
[0037] FIG. 4 is a schematic block diagram showing an exemplary functional configuration
of a controller 600 for controlling a variety of the aforementioned operations of
the post-processing apparatus 100. The controller 600 is described with reference
to FIGS. 2 and 4. The solid line in FIG. 4 conceptually indicates signal transmission.
The dotted line in FIG. 4 conceptually indicates force transmission.
[0038] The controller 600 controls the second ejector 220, the pulling-back mechanism 500,
the first and second blowers 410, 420. The second ejector 220 includes a roller driver
223 and a roller displacement portion 224 in addition to the rollers 221, 222. The
roller driver 223 bi-directionally rotates the roller 221. The roller displacement
portion 224 displaces the roller 222 between the adjacent position and the distant
position. The pulling-back mechanism 500 includes a paddle driver 530, in addition
to the rotary shaft 510 and the paddle arm 520. The paddle drive mechanism 530 rotates
the rotary shaft 510.
[0039] The controller 600 includes a sheet detector 610, an ejection controller 620, a pulling-back
controller 630, a blower controller 640 and a counter 650. The sheet detector 610
detects a sheet ejected from the first ejector 210, and a sheet on the first tray
310. The sheet detector 610 detecting the sheet generates a detection signal indicative
of the detection of the sheet. The detection signal is output from the sheet detector
610 to each of the ejection controller 620, the pulling-back controller 630 and the
blower controller 640. The ejection controller 620 controls the second blower 220
in response to the detection signal. The pulling-back controller 630 controls the
pulling-back mechanism 500 in response to the detection signal. The blower controller
640 controls the first and second blowers 410, 420 in response to the detection signal.
The counter 650 counts sheets on the basis of the detection signal to perform a given
determination process. In addition, the counter 650 outputs a given operation instruction
on the basis of a result of the determination process to each of the ejection controller
620, the blower controller 640 and the stapler 110.
[0040] FIG. 5 is a schematic timing chart of the detection signal output from the sheet
detector 610. The sheet detector 610 is described with reference to FIGS. 1, 2, 4
and 5.
[0041] The sheet detector 610 includes a first detector 611 and a second detector 612. The
first detector 611 detects a sheet (i.e. the first sheet or the subsequent sheet)
ejected from the first ejector 210. The second detector 612 detects a sheet on the
first tray 310.
[0042] The first detector 611 may be a transmissive optical sensor situated just after the
first ejector 210. The first detector 611 generates a first detection signal. The
first detector 611 outputs a high voltage signal as the first detection signal when
a sheet blocks an optical path which is formed downstream of the first ejector 210
by the first detector 611. Otherwise, the first detector 611 outputs a low voltage
signal as the first detection signal. A change from the low voltage to the high voltage
indicates that a downstream end (downstream edge in the ejection direction) of a sheet
blocks the optical path formed downstream of the first ejector 210. A change from
the high voltage to the low voltage indicates that an upstream end (upstream edge
in the ejection direction) of the sheet passes through the optical path formed downstream
of the first ejector 210. The first detector 611 may be any other type of sensor as
long as it is capable of detecting the start and the end of the ejection of a sheet
from the first ejector 210. The principle of the present embodiment is not limited
to a specific sensor used as the first detector 611.
[0043] The second detector 612 may be a reflective optical sensor attached to the first
tray 310. The second detector 612 generates a second detection signal at a low voltage
when there is no sheet on the first tray 310. When the first sheet is supplied onto
the first tray 310, the first sheet reflects detective light emitted from the second
detector 612. The second detector 612 receives the detective light reflected by the
first sheet and generates the second detection signal at a high voltage. A change
from the low voltage to the high voltage indicates that the first sheet is placed
on the first tray 310. A change from the high voltage to the low voltage indicates
that a sheet stack is ejected from the first tray 310 to the second tray 320.
[0044] The counter 650 determines how many sheets have been ejected from the first ejector
210 to form a sheet stack, on the basis of the first detection signal output from
the first detector 611. The counter 650 includes a determination portion 651, an ejection
request portion 652 and an operation request portion 653. The determination portion
651 performs a given determination process on the basis of the first detection signal.
The ejection request portion 652 outputs an operation instruction to the ejection
controller 620 on the basis of a result of the determination process of the determination
portion 651. The operation request portion 653 outputs an operation instruction to
the stapler 110 on the basis of a result of the determination process of the determination
portion 651.
[0045] The determination portion 651 receives the first detection signal (c.f. FIG. 4) from
the first detector 611. The determination portion 651 counts pulses of the first detection
signal to generate a count value. The count value is indicative of how many sheets
have passed through the first ejector 210. The determination portion 651 also receives
sheet stack information from the image forming apparatus IFA, in addition to the first
signal. The sheet stack information is indicative of the total number of sheets which
have been supplied from the image forming apparatus IFA to the post-processing apparatus
100. The counter 650 compares the count value with the total sheet number indicated
by the sheet stack information.
[0046] The ejection request portion 652 generates an ejection request in response to a result
of the comparison between the count value and the total sheet number. The ejection
request is output from the ejection request portion 652 to the ejection controller
620. The ejection controller 620 controls the second ejector 220 in response to the
ejection request. The second ejector 220 ejects the sheet stack from the first tray
310 to the second tray 320 under control of the ejection controller 620.
[0047] Before ejecting the sheet stack from the first tray 310 to the second tray 320, the
operation request portion 653 generates an operation request in response to the result
of the comparison between the count value and the total sheet number. The operation
request is output from the operation request portion 653 to the stapler 110. In response
to the operation request, the stapler 110 is operated to staple the sheet stack.
[0048] FIG. 6 is a schematic flowchart showing operations of the determination portion 651
to notify a determination result to the operation request portion 653 and the ejection
request portion 652 which generate the operation request and the ejection request,
respectively. The operations of the determination portion 651 are described below
with reference to FIGS. 4 and 6.
(Step S110)
[0049] The determination portion 651 waits for the sheet stack information. Once the determination
portion 651 receives the sheet stack information from the image forming apparatus
IFA, step S120 is executed.
(Step S120)
[0050] The determination portion 651 sets the count value to "0". Step S130 is then executed.
(Step S130)
[0051] The determination portion 651 refers to the first detection signal, and waits for
a change from a low voltage level to a high voltage level in the first detection signal.
When there is the change from the low voltage level to the high voltage level, step
S140 is executed.
(Step S140)
[0052] The determination portion 651 adds "1" to the count value. Step S150 is then executed.
(Step S150)
[0053] The determination portion 651 compares the count value with the total sheet number
indicated by the sheet stack information, to determine whether or not the counter
value is coincident with the total sheet number. A sheet in correspondence to a count
value which is coincident with the total sheet number is a second sheet which is the
last sheet ejected from the first ejector 210 in a sheet stack. When the count value
becomes coincident with the total sheet number, step S160 is executed. Otherwise,
the step S130 is executed.
(Step S160)
[0054] It is notified from the determination portion 651 to each of the ejection request
portion 652 and the operation request portion 653 that the count value becomes coincident
with the total sheet value. The ejection request portion 652 generates an ejection
request in response to the notification from the determination portion 651. The ejection
request is output from the ejection request portion 652 to the ejection controller
620. The ejection controller 620 controls the second ejector 220 in response to the
ejection request. Under control of the ejection controller 620, the second ejector
220 ejects a sheet stack from the first tray 310 to the second tray 320. Like the
ejection request portion 652, the operation request portion 653 receiving the notification
from the determination portion 651 generates an operation request in response to the
notification from the determination portion 651. The operation request is output from
the operation request portion 653 to the stapler 110. In response to the operation
request, the stapler 110 is operated to staple the sheet stack. These output timings
of the ejection request and the operation request are adjusted in the counter 650
so that the operation request is output before the ejection request. Therefore, the
second ejector 220 may perform an ejection operation under control of the ejection
controller 620 after the stapler 110 stapling the sheet stack.
[0055] The ejection controller 620 receives not only the ejection request from the counter
650 but also the detection signal from the sheet detector 610. The ejection controller
620 includes a drive controller 621 for controlling the roller driver 223 in response
to the detection signal and the ejection request, and a displacement controller 622
for controlling the roller displacement portion 224 in response to the detection signal
and the ejection request. Operations of the drive controller 621 and the displacement
controller 622 are described below with reference to FIGS. 7 and 8.
[0056] FIG. 7 is a schematic flowchart showing operations of the drive controller 621. The
operations of the drive controller 621 are described with reference to FIGS. 1, 4,
6 and 7.
(Step S210)
[0057] The drive controller 621 refers to the first detection signal output from the first
detector 611, and waits for a change from the low voltage level to the high voltage
level in the first detection signal. The change from the low voltage level to the
high voltage level means that the first ejector 210 starts the ejection of the first
sheet. When there is the change from the low voltage level to the high voltage level,
step S220 is executed.
(Step S220)
[0058] The drive controller 621 generates a rotation control signal for requesting that
the roller 221 is rotated so that the first sheet is moved in the ejection direction.
The rotation control signal is output from the drive controller 621 to the roller
driver 223. The roller driver 223 rotates the roller 221 in response to the rotation
control signal. Accordingly, the first sheet is conveyed in the ejection direction.
After the generation of the rotation control signal, step S230 is executed.
(Step S230)
[0059] The drive controller 621 refers to the first detection signal to determine whether
or not the high voltage level in the first detection signal has changed to the low
voltage level. The change from the high voltage level to the low voltage level means
that the first ejector 210 completes the ejection of the first sheet. If it is determined
that the high voltage level has changed to the low voltage level, step S240 is executed.
Otherwise, the step S220 is executed.
(Step S240)
[0060] The drive controller 621 generates a rotation control signal for requesting that
the roller 221 is rotated so that the first sheet is moved in the pulling-back direction.
The rotation control signal is output from the drive controller 621 to the roller
driver 223. The roller driver 223 rotates the roller 221 in response to the rotation
control signal. Accordingly, the first sheet is conveyed in the pulling-back direction.
After the generation of the rotation control signal, step S250 is executed.
(Step S250)
[0061] The drive controller 621 refers to the second detection signal output from the second
detector 612 to determine whether or not the low voltage level in the second detection
signal has changed to the high voltage level. The change from the low voltage level
to the high voltage level means that the first sheet is set in position on the first
tray 310. If it is determined that the low voltage level has changed to the high voltage
level, step S260 is executed. Otherwise, the step S240 is executed.
(Step S260)
[0062] The drive controller 621 stops outputting the rotation control signal. Consequently,
the roller driver 223 stops the roller 221. After the stop of the output of the rotation
control signal, step S270 is executed.
(Step S270)
[0063] The drive controller 621 waits for the ejection request. As described with reference
to FIG. 6, the ejection request is generated when the second sheet (i.e. the last
sheet in the sheet stack) is ejected from the first ejector 210. When the drive controller
621 receives the ejection request from the ejection request portion 652, step S280
is executed.
(Step S280)
[0064] The drive controller 621 generates a rotation control signal for requesting a rotation
of the roller 221 so that the sheet stack is moved in the ejection direction. The
rotation control signal is output from the drive controller 621 to the roller driver
223 for a given time period. The roller driver 223 rotates the roller 221 in response
to the rotation control signal for the given time period. Accordingly, the sheet stack
is conveyed in the ejection direction, and ejected from the first tray 310 to the
second tray 320.
[0065] FIG. 8 is a schematic flowchart showing operations of the displacement controller
622. The operations of the displacement controller 622 are described with reference
to FIGS. 1, 4, 6 and 8.
(Step S310)
[0066] The displacement controller 622 refers to the first detection signal output from
the first detector 611, and waits for a change from the low voltage level to the high
voltage level in the first detection signal. The change from the low voltage level
to the high voltage level means that the first ejector 210 starts the ejection of
the first sheet. When there is the change from the low voltage level to the high voltage
level, step S320 is executed.
(Step S320)
[0067] The displacement controller 622 generates a displacement control signal for requesting
a downward movement of the roller 222 of the second ejector 220. The displacement
control signal is output from the displacement controller 622 to the roller displacement
portion 224. The roller displacement portion 224 moves the roller 222 downwardly in
response to the displacement control signal. Accordingly, the first sheet is nipped
between the rollers 221, 222 of the second ejector 220. Therefore, the rotation of
the roller 221 is efficiently transmitted to the first sheet. After the generation
of the displacement control signal, step S330 is executed.
(Step S330)
[0068] The displacement controller 622 refers to the second detection signal output from
the second detector 612, and waits for a change from the low voltage level to the
high voltage level in the second detection signal. The change from the low voltage
level to the high voltage level means that the first sheet is set in position on the
first tray 310. When there is the change from the low voltage level to the high voltage
level, step S340 is executed.
(Step S340)
[0069] The displacement controller 622 generates a displacement control signal for requesting
an upward movement of the roller 222. The displacement control signal is output from
the displacement controller 622 to the roller displacement portion 224. The roller
displacement portion 224 moves the roller 222 upwardly in response to the displacement
control signal. Accordingly, the roller 222 is moved upwardly away from the roller
221. After the generation of the displacement control signal, step S350 is executed.
(Step S350)
[0070] The displacement controller 622 waits for the ejection request. As described with
reference to FIG. 6, the ejection request is generated when the second sheet (i.e.
the last sheet in a sheet stack) is ejected from the first ejector 210. While the
displacement controller 622 waits for the ejection request, the subsequent sheet sent
from the first ejector 210 in the ejection direction may be moved in the ejection
direction through the gap formed between the rollers 221, 222, the gap resulting from
the upward movement of the roller 222. In addition, the subsequent sheet ejected from
the first ejector 210 is conveyed in the pulling-back direction by the pulling-back
mechanism 500 through the gap between the rollers 221, 222. Accordingly, sheets are
stacked on the first tray 310 to form a sheet stack. The sheet stack partially protrudes
from the second ejector 220 in the ejection direction through the gap between the
rollers 221, 222. When the displacement controller 622 receives the ejection request
from the ejection request portion 652, step S360 is executed.
(Step S360)
[0071] The displacement controller 622 generates the displacement control signal for requesting
the downward movement of the roller 222. The displacement control signal is output
from the displacement controller 622 to the roller displacement portion 224. The roller
displacement portion 224 moves the roller 222 downwardly in response to the displacement
control signal. Accordingly, the sheet stack is nipped between the rollers 221, 222.
Therefore, the rotation of the roller 221 is efficiently transmitted to the sheet
stack.
[0072] The second ejector 220 controlled by the displacement controller 622 and the drive
controller 621 conveys the first sheet in the pulling-back direction whereas the pulling-back
mechanism 500 conveys the subsequent sheet in the pulling-back direction after the
subsequent sheet has been ejected from the first ejector 210 subsequently to the first
sheet. Operations of the pulling-back controller 630 for controlling the pulling-back
mechanism 500 are described below.
[0073] FIG. 9 is a schematic flowchart showing the operations of the pulling-back controller
630. The operations of the pulling-back controller 630 are described with reference
to FIGS. 2, 4, 6 and 9.
(Step S410)
[0074] The displacement controller 630 refers to the second detection signal output from
the second detector 612, and waits for a change from the low voltage level to the
high voltage level in the second detection signal. The change from the low voltage
level to the high voltage level means that the first sheet is set in position on the
first tray 310. When there is the change from the low voltage level to the high voltage
level, step S420 is executed.
(Step S420)
[0075] The pulling-back controller 630 refers to the first detection signal output from
the first detector 611 to determine whether or not the high voltage level in the first
detection signal has changed to the low voltage level. The change from the high voltage
level to the low voltage level means that the first ejector 210 has completed the
ejection of the first sheet. If it is determined that the high voltage level has changed
to the low voltage level, step S430 is executed.
(Step S430)
[0076] The pulling-back controller 630 generates a pulling-back control signal for a given
time period. The pulling-back control signal is output from the pulling-back controller
630 to the paddle driver 530. The paddle driver 530 rotates the rotary shaft 510 in
response to the pulling-back control signal for the given time period. Accordingly,
the paddle arm 520 sends the subsequent sheet in the pulling-back direction for the
given time period, so that the subsequent sheet is supplied onto the first tray 310.
After the generation of the pulling-back control signal by the pulling-back controller
630 for the given time period, step S440 is executed.
(Step S440)
[0077] The pulling-back controller 630 determines whether or not the ejection signal has
been received. As described with reference to FIG. 6, the ejection request is generated
when the second sheet (i.e. the last sheet in a sheet stack) is ejected from the first
ejector 210. When the pulling-back controller 630 receives the ejection request from
the ejection request portion 652, the processes of the pulling-back controller 630
is terminated. Otherwise, the step S420 is executed.
[0078] While the pulling-back controller 630 and the ejection controller 620 control the
sheet conveyance operation, the blower controller 640 controls the first and second
blowers 410, 420. Operations of the blower controller 640 are described below.
[0079] FIG. 10 is a schematic flowchart showing the operations of the blower controller
640. The operations of the blower controller 640 are described with reference to FIGS.
1, 4, 6 and 10.
[0080] As shown in FIG. 4, the blower controller 640 includes a first blower controller
641 and a second blower controller 642. The first blower controller 641 controls the
first blower 410 in response to a detection signal from the sheet detector 610. The
second blower controller 642 controls the second blower 420 in response to a detection
signal from the sheet detector 610. Control operations of the first and second blower
controllers 641, 642 are described below with reference to FIG. 10.
(Step S510)
[0081] The blower controller 640 refers to the first detection signal, and waits for a change
from the low voltage level to the high voltage level in the first detection signal.
The change from the low voltage level to the high voltage level means that the first
ejector 210 starts the ejection of the first sheet. When there is the change from
the low voltage level to the high voltage level, step S520 is executed.
(Step S520)
[0082] Each of the first and second blower controllers 641, 642 generates an air-blow control
signal. The air-blow control signal is output from the first and second blower controllers
641, 642 to the first and second blowers 410, 420, respectively. Each of the first
and second blowers 410, 420 blows air in response to the air-blow control signal.
The air-blow from the first blower 410 causes airflow between the lower surface of
the first sheet and the support surface 323 of the second tray 320. Accordingly, there
is a significant reduction in frictional force between the first sheet and the second
tray 320. Therefore, the first sheet may be smoothly moved in the ejection direction.
Meanwhile, the second blower 420 continues the air-blow onto the first sheet, so that
a curvature deformation of the first sheet is facilitated. Consequently, the first
sheet over the second tray 320 moves away from an ejection path of the subsequent
sheet. Therefore, the subsequent sheet becomes less likely to come into close contact
with the preceding sheet. After the generation of the air-blow control signal, step
S530 is executed.
(Step S530)
[0083] The first blower controller 641 refers to the first detection signal, and waits for
a change from the high voltage level to the low voltage level in the first detection
signal. The change from the high voltage level to the low voltage level means that
the first ejector 210 has completed the ejection of the subsequent sheet. When the
high voltage level has changed to the low voltage level, step S540 is executed.
(Step S540)
[0084] The first blower controller 641 stops generating the air-blow control signal. Accordingly,
the first blower 410 stops blowing the air. On the other hand, the second blower controller
642 continues to generate the air-blow control signal, so that the second blower 420
continues the air-blow. Therefore, the first sheet is curved downwardly over the second
tray 320. Therefore, there is no excessively strong sliding friction between the first
sheet and the subsequent sheet. After the stop of the generation of the air-blow control
signal, step S550 is executed.
(Step S550)
[0085] The second blower controller 642 waits for the ejection request. The ejection request
is generated when the second sheet (i.e. the last sheet in a sheet stack) is ejected
from the first ejector 210. When the second blower controller 642 receives the ejection
request from the ejection request portion 652, step S560 is executed.
(Step S560)
[0086] The second blower controller 642 stops generating the air-blow control signal. Accordingly,
the second blower 420 stops blowing the air.
[0087] The aforementioned step S530 may be replaced by any other suitable determination
processes. For example, the first blower controller 641 may refer to the second detection
signal to determine whether or not the low voltage level in the second detection signal
has changed to the high voltage level. The change from the low voltage level to the
high voltage level means that the first sheet is set in position on the first tray
310. If it is determined that the low voltage level has changed to the high voltage
level, the step S540 may be executed.
< Restart of Air-Blow from First Blower >
[0088] In regard to the control described with reference to FIG. 10, the air-blow from the
first blower 410 (c.f. FIG. 1) is stopped in the step S540. However, the first blower
410 may be activated after elapse of the second time period shown in FIG. 3 to restart
the air-blow from the first blower 410. By restarting the air-blow from the first
blower 410, the first sheet pressed against the second tray 320 (c.f. FIG. 1) by the
weight of subsequent sheets stacked on the first sheet becomes less likely to come
into close contact with the second tray 320. Operations of restarting the air-blow
from the first blower 410 are controlled by the determination portion 651 of the counter
650 and the first blower controller 641 of the blower controller 640. Processes which
are executed by the determination portion 651 and the first blower controller 641
so as to restart the air-blow from the first blower 410 are described below with reference
to FIGS. 11 and 12.
[0089] FIG. 11 is a schematic flowchart showing the processes which are executed by the
determination portion 651 of the counter 650. The operations of the determination
portion 651 are described with reference to FIGS. 4, 6 and 11.
(Step S151)
[0090] The processes for restarting the air-blow from the first blower 410 may be performed
in the step S150 described with reference to FIG. 6. Therefore, step S151 is performed
just after the step S140. The determination portion 651 compares the total sheet number
indicated by the sheet stack information with a given count threshold. If the total
sheet number is less than the given count threshold, step S153 is executed. Otherwise,
step S155 is executed.
(Step S153)
[0091] The determination portion 651 sets the count threshold to a value of the total sheet
number. Subsequently, the step S155 is executed.
(Step S155)
[0092] The determination portion 651 compares the count value with the count threshold.
If the count value is coincident with the count threshold, step S157 is executed.
Otherwise, the step S130 is executed.
(Step S157)
[0093] The determination portion 651 generates a restart request. The restart request is
output from the determination portion 651 to the first blower controller 641. After
the generation of the restart request, step S159 is executed.
(Step S159)
[0094] The determination portion 651 compares the count value with the total sheet number
indicated by the sheet stack information. When the count value is coincident with
the total sheet number, the step S160 is executed. Otherwise, the step S130 is executed.
[0095] FIG. 12 is a schematic flowchart showing processes of the first blower controller
641. The processes of the first blower controller 641 are described with reference
to FIGS. 4, 6, and 10 to 12.
(Step S541)
[0096] The processes for restarting the air-blow from the first blower 410 may be performed
in the step S540 described with reference to FIG. 10. Therefore, step S541 is performed
just after the step S530. The first blower controller 641 waits for the restart request
generated in the step S157 of FIG. 11. When the first blower controller 641 receives
the restart request from the determination portion 651, step S543 is executed.
(Step S543)
[0097] The first blower controller 641 generates an air-blow control signal. The air-blow
control signal is output from the first blower controller 641 to the first blower
410. The first blower 410 restarts the air-blow in response to the air-blow control
signal. Air from the first blower 410 is blown into a boundary between the lower surface
of the first sheet and the support surface 323 of the second tray 320. Accordingly,
the first sheet becomes less likely to come into close contact with the second tray
320. After the generation of the air-blow control signal, step S545 is executed.
(Step S545)
[0098] The first blower controller 641 waits for the ejection request. As described with
reference to FIG. 6, the ejection request is generated when the second sheet (i.e.
the last sheet in a sheet stack) is ejected from the first ejector 210. When the first
blower controller 641 receives the ejection request from the ejection request portion
652, step S547 is executed.
(Step S547)
[0099] The first blower controller 641 stops generating the air-blow control signal. Accordingly,
the first blower 410 stops the air-blow.
(Control according to Sheet Size)
[0100] If a sheet is short in the ejection direction, a contact area between the first sheet
and the subsequent sheet does not become too large. Therefore, the first sheet is
less likely to interfere with pulling-back of the subsequent sheet. In this case,
the air-blow from the first and second blowers 410, 420 results in wasting electric
power of the post-processing apparatus 100. An exemplary control depending on a sheet
size is described below.
[0101] As shown in FIG. 4, sheet size information indicative of a sheet length in the ejection
direction may be output from the image forming apparatus IFA to the blower controller
640. For example, the sheet size information may include "A4 size", and "lateral orientation
(i.e. a short side of the first sheet is oriented substantially in parallel to the
ejection direction)". The blower controller 640 refers to the sheet size information
to determine whether or not the air-blow from the first and second blowers 410, 420
should be performed.
[0102] FIG. 13 is a schematic flowchart showing exemplary processes which are executed by
the blower controller 640 so as to determine whether or not the air-blow should be
performed. The exemplary processes of the blower controller 640 are described with
reference to FIGS. 4, 10 and 13.
(Step S501)
[0103] The blower controller 640 waits for the sheet size information. When the blower controller
640 receives the sheet size information, step S503 is executed.
(Step S503)
[0104] The blower controller 640 refers to the sheet size information to identify the sheet
length in the ejection direction. The blower controller 640 compares the sheet length
with a given length threshold. If the sheet length is greater than the length threshold,
the step S510 is executed. Accordingly, the series of processes described with reference
to FIG. 10 is executed. On the other hand, if the sheet length is not greater than
the length threshold, the blower controller 640 terminates the processes. In this
case, the first and second blowers 410, 420 do not blow air.
[0105] The length threshold may be set so that the step S510 is executed when a sheet area
more than one-half of the entire surface protrudes from the first tray 310. However,
the principle of the present embodiment is not limited to a specific value of the
length threshold. According to the processing flow shown in FIG. 13, when the sheet
length is not greater than the length threshold, the first and second blowers 410,
420 are stopped. However, the first and second blowers 410, 420 may blow air, irrespective
of the sheet length.
< Drive of Second Tray >
[0106] The post-processing apparatus 100 is designed so that the second tray 320 is moved
vertically. The drive of the second tray 320 is described below.
[0107] FIG. 14 is a schematic block diagram showing an exemplary functional configuration
of the post-processing apparatus 100. The post-processing apparatus 100 is further
described with reference to FIGS. 1, 6 and 14. The solid line in FIG. 14 conceptually
indicates signal transmission. The dotted line in FIG. 14 conceptually indicates force
transmission. The one-dot chain line in FIG. 14 conceptually indicates detection operation.
[0108] The post-processing apparatus 100 further includes a tray driver 324 for driving
the second tray 320. The tray driver 324 moves the second tray 320 downwardly from
a first height position (the position of the second tray 320 shown in FIG. 1) under
control of the controller 600. The tray driver 324 may include a motor (not shown),
and a transmission mechanism (e.g. a combination of a belt and a pulley: not shown)
designed to convert torque from the motor into a vertical movement of the second tray
320. Alternatively, the tray driver 324 may include a cylinder device (not shown)
coupled to the second tray 320. The principle of the present embodiment is not limited
to a specific mechanism of the tray driver 324.
[0109] The controller 600 further includes a tray controller 660 for controlling the tray
driver 324, and a tray detector 670 for detecting the second tray 320. The tray detector
670 generates a tray detection signal when the tray detector 670 detects the second
tray 320. The tray detection signal is output to the tray controller 660. The tray
controller 660 receives signals from the determination portion 651 and the first detector
611. It is notified from the determination portion 651 not only to the ejection request
portion 652 and the operation request portion 653 but also the tray controller 660
that the count value becomes coincident with the total sheet number. The first detector
611 outputs the first detection signal to the tray controller 660. The tray controller
660 controls the tray driver 324 on the basis of the tray detection signal, the first
detection signal and the notification from the determination portion 651.
[0110] The tray detector 670 for outputting the tray detection signal to the tray controller
660 includes a timer 671 and an upper tray sensor 672. The timer 671 is used to measure
a length of a time period during which the second tray 320 is moved downwardly. The
upper tray sensor 672 is used to detect an upper surface of a sheet stack on the second
tray 320. The upper tray sensor 672 may be a reflective optical sensor forming a detection
region defined at a second height position higher than the first height position.
The tray driver 324 moves the second tray 320 upwardly under control of the tray controller
660 until the upper tray sensor 672 detects the second tray 320.
[0111] FIG. 15 is a schematic flowchart showing exemplary processes which are executed by
the tray controller 660. The operations of the tray controller 660 are described with
reference to FIGS. 1, 6, 14 and 15.
(Step S610)
[0112] The tray controller 660 refers to the first detection signal, and waits for a change
from the high voltage level to the low voltage level in the first detection signal.
The change from the high voltage level to the low voltage level means that the first
ejector 210 completes the ejection of the first sheet. When there is the change from
the high voltage level to the low voltage level, step S620 is executed.
(Step S620)
[0113] The tray controller 660 generates a drive signal for causing the downward movement
of the second tray 320. The drive signal is output from the tray controller 660 to
the tray driver 324. The tray driver 324 moves the second tray 320 downwardly in response
to the drive signal. Accordingly, there is an increase in distance from the roller
221 of the second ejector 220 to the proximal end 321 of the second tray 320. Since
the second blower 420 blows air downwardly as mentioned above, the first sheet is
largely curved downwardly. Therefore, the subsequent sheet is not excessively strongly
rubbed with the first sheet. After the generation of the drive signal, step S630 is
executed.
(Step S630)
[0114] When the second try 320 is moved downwardly under control of the tray controller
660, a voltage of the tray detection signal output from the upper tray sensor 672
changes from a high voltage level to a low voltage level (i.e. a change from a condition
in which the upper tray sensor 672 detects the upper surface of a sheet stack on the
second tray 320 to a condition in which the upper tray sensor 672 does not detect
the upper surface of the sheet stack on the second tray 320). When there is a change
in the voltage of the tray detection signal from the high level to the low level,
the timer 671 starts measuring time. After the elapse of a given time period from
a start time of the time measurement, the timer 671 generates a stop trigger. The
stop trigger is output from the timer 671 to the tray controller 660. In the step
S630, the tray controller 660 waits for receiving the stop trigger from the timer
671. When the tray controller 660 receives the stop trigger from the timer 671, step
S640 is executed.
(Step S640)
[0115] The tray controller 660 stops generating the drive signal in response to receiving
the stop trigger. Accordingly, the tray driver 324 and the second tray 320 are stopped.
After the stop of the generation of the drive signal, step S650 is executed.
(Step S650)
[0116] The tray controller 660 waits the notification from the determination portion 651.
As described with reference to FIG. 6, the notification from the determination portion
651 is generated when the second sheet (i.e. the last sheet in a sheet stack) is ejected
from the first ejector 210. When the tray controller 660 receives the notification
from the determination portion 651, step S660 is executed.
(Step S660)
[0117] The tray controller 660 generates a drive signal for causing an upward movement of
the second tray 320. The drive signal is output from the tray controller 660 to the
tray driver 324. The tray driver 324 moves the second tray 320 upwardly in response
to the drive signal. After the generation of the drive signal, step S670 is executed.
(Step S670)
[0118] The tray controller 660 waits for receiving the tray detection signal from the upper
tray sensor 672. When the tray controller 660 receives the tray detection signal from
the upper tray sensor 672, step S680 is executed.
(Step S680)
[0119] The tray controller 660 stops generating the drive signal. Accordingly, the tray
driver 324 and the second tray 320 are stopped. Since the second tray 320 is stopped
at the second height position higher than the position shown in FIG. 1 at this time,
there is a very small difference in height between the roller 221 of the second ejector
220 and the second tray 320. Therefore, a sheet stack formed on the first tray 310
may be smoothly ejected to the second tray 320.
< Control of Second Tray based on Size of First Sheet >
[0120] If the first sheet temporarily held in the first tray 310 largely protrudes from
the first tray 310 toward the second tray 320, a contact area between the first sheet
and the subsequent sheet becomes significantly large. In this case, the first sheet
becomes more likely to be pushed in the ejection direction by the subsequent sheet.
On the other hand, if the first sheet does not protrude from the first tray 310 toward
the second tray 320 so much, there may be a small contact area between the first sheet
and the subsequent sheet. In this case, the first sheet is less likely to be pushed
in the ejection direction by the subsequent sheet. In short, the first sheet is appropriately
held by the first tray 310 without the downward movement of the second tray 320. Control
of the downward movement of the second tray 320 on the basis of the size of the first
sheet is described blow.
[0121] FIG. 16 is a schematic flowchart showing operations of the tray controller 660. The
operations of the tray controller 660 are described with reference to FIGS. 3 to 5
and 16.
[0122] Steps S611 to S617 shown in FIG. 16 are processes in the step S610 described with
reference to FIG. 15. Through the processes of the steps S611 to S617, it is determined
whether or not the step S620 (generation of the drive signal for moving the second
tray 320 downwardly) described with reference to FIG. 15 should be performed.
(Step S611)
[0123] The tray controller 660 waits for a change from the low voltage level to the high
voltage level in the first detection signal (c.f. FIG. 5). When there is the change
from the low voltage level to the high voltage level in the first detection signal,
the tray controller 660 stores a clock time when the change from the low voltage level
to the high voltage level has happened to the first detection signal. Step S613 is
then executed.
(Step S613)
[0124] The tray controller 660 waits for a change from the high voltage level to the low
voltage level in the first detection signal (c.f. FIG. 5). When there is the change
from the high voltage level to the low voltage level in the first detection signal,
the tray controller 660 stores a clock time when the change from the high voltage
level to the low voltage level has happened to the first detection signal. Step S615
is then executed.
(Step S615)
[0125] The tray controller 660 subtracts the time clock data stored in the step S613 from
the time clock data stored in the step S611. Consequently, the tray controller 660
may calculate a time length of the first period described with reference to FIG. 3.
The tray controller 660 multiplies the calculated time length by an ejection speed
of the first sheet. The ejection speed of the first speed is a predetermined fixed
value. As a result of the multiplication, the tray controller 660 may obtain data
about the length of the first sheet in the ejection direction. After the calculation
of the length of the first sheet, step S617 is executed.
(Step S617)
[0126] The tray controller 660 compares the length of the first sheet with a given threshold.
If the length of the first sheet is greater than the threshold, the step S620 is executed.
The given threshold may be set so that the step S620 is executed when an area more
than one-half of the entire surface region of the first sheet protrudes from the first
tray 310. If the length of the first sheet is not greater than the threshold, the
tray controller 660 terminates the process. Accordingly, the second tray 320 is stayed
at the first height position without being unnecessarily moved downwardly. In short,
the post-processing apparatus 100 may avoid wasting electric power.
[0127] The tray controller 660 calculates the length of the first sheet on the basis of
the first detection signal. Alternatively, like the blower controller 640 in FIG.
13, the tray controller 660 may receive the sheet size information from the image
forming apparatus IFA to obtain information indicative of the length of the first
sheet from the received sheet size information. On the other hand, the blower controller
640 may calculate the length of the first sheet by executing the same calculation
process as the calculation shown in FIG. 16 (the steps S611 to S615).
< Alignment Portion >
[0128] The first tray 310 performs an alignment operation of adjusting positions of sheets
stacked on the support surface 318 of the first tray 310b so that edges of the sheets
on the first tray 310 overlap each other. The alignment operation of the first tray
310 is described below.
[0129] FIG. 17 is a schematic plan view of the first tray 310. The alignment operation of
the first tray 310 is described with reference to FIGS. 4 and 17.
[0130] The first tray 310 includes a support plate 312 forming the support surface 318,
two cursors 313, 314, a stopper 315, a motor (not shown) for driving the cursors 313,
314. The support plate 312 supports the first sheet and at least one subsequent sheet,
which are sequentially ejected from the first ejector 210. The cursors 313, 314 are
driven by the motor so as to adjust a position of lateral edges of the sheets on the
support plate 312. A position of the upstream edges (edges of the upstream side in
the ejection direction) of the sheets on the support plate 321 is set by the stopper
315. Each of the cursors 313, 314 and the stopper 315 stands upwardly from the upper
surface of the support plate 312. By the stopper 315, the cursors 313, 314 and the
motor, which drives the cursors 313 314, an alignment portion 311 is formed.
[0131] The stopper 315 is situated so that the upstream edges of the first sheet and the
subsequent sheet hit the stopper 315. A detection position of the second detector
612 is set near the stopper 315. The second detector 612 outputs the second detection
signal when the upstream edges of the first sheet moves into the detection position
of the second detector 612.
[0132] The motor reciprocates the cursors 313, 314 in a direction orthogonal to the ejection
direction in response to the second detection signal. Any of techniques used in various
sheet alignment mechanisms incorporated in known post-processing apparatuses may be
applied to a conversion mechanism for converting rotation of the motor into linear
reciprocation of the cursors 313, 314. Therefore, the principle of the present embodiment
is not limited to a specific conversion mechanism.
[0133] Operation of the alignment portion 311 is described below.
[0134] When sheets are sequentially sent in the pulling-back direction by the second ejector
220 and the pulling-back mechanism 500, upstream edges of these sheets hit the stopper
315. Accordingly, a position of the sheets in the ejection direction is fixed. Subsequently,
the cursors 313, 314 are moved in directions causing them to come closer to each other.
Consequently, a position of the sheets is appropriately adjusted in the direction
orthogonal to the ejection direction so that the lateral sheet edges in a sheet stack
overlap each other.
[0135] Subsequently, the cursors 313, 314 are moved in directions causing them to come away
from each other. Accordingly, the subsequent sheet may enter a region between the
cursors 313, 314 without interference with the cursors 313, 314.
[0136] The cursors 313, 314 are reciprocated after the pulling-back operation of the pulling-back
mechanism 500. Therefore, the cursors 313, 314 are reciprocated in collaboration with
the pulling-back operation of the pulling-back mechanism 500 under control of the
pulling-back controller 630. Processes of the pulling-back controller 630 are described
below.
[0137] FIG. 18 is a schematic flowchart showing exemplary processes which are executed by
the pulling-back controller 630 in the step S430 (c.f. FIG. 9). The processes of the
pulling-back controller 630 are described with reference to FIGS. 2, 4 and 18.
(Step S431)
[0138] The pulling-back controller 630 starts a time measurement. A time measurement value
is increased from "0". When the pulling-back controller 630 starts the time measurement,
step S433 is executed.
(Step S433)
[0139] The pulling-back controller 630 generates the pulling-back control signal. The pulling-back
control signal is output from the pulling-back controller 630 to the paddle driver
530. The paddle driver 530 rotates the rotary shaft 510 in response to the pulling-back
control signal. Accordingly, the paddle arm 520 sends the subsequent sheet in the
pulling-back direction, so that the subsequent sheet is supplied onto the first tray
310. When the pulling-back controller 630 generates the pulling-back control signal,
step S435 is executed.
(Step S435)
[0140] The pulling-back controller 630 compares the time measurement value with a given
time measurement threshold. If the time measurement value is greater than the time
measurement threshold, step S437 is executed.
(Step S437)
[0141] The generation of the pulling-back control signal by the pulling-back controller
630 is stopped. Accordingly, the paddle driver 530 is stopped so that the pulling-back
operation of the pulling-back mechanism 500 is terminated. After the stop of the generation
of the pulling-back control signal, step S439 is executed.
(Step S439)
[0142] The pulling-back controller 630 generates an alignment request.
[0143] FIG. 19 is a schematic block diagram showing an exemplary functional configuration
to make the aligning operation of the alignment portion 311 in collaboration with
the pulling-back operation of the pulling-back mechanism 500. The post-processing
apparatus 100 is further described with reference to FIGS. 18 and 19.
[0144] The controller 600 further includes an alignment controller 680 for controlling the
alignment portion 311. The alignment request generated in the step S439 is output
from the pulling-back controller 630 to the alignment controller 680. The alignment
controller 680 receives the second detection signal from the second detector 612 in
addition to the alignment request.
[0145] When the second detection signal changes from the low voltage level to the high voltage
level, the alignment controller 680 generates an alignment control signal. The alignment
control signal is output from the alignment controller 680 to the alignment portion
311. Therefore, the cursors 313, 314 are reciprocated in the directions substantially
perpendicular to the ejection direction in response to the alignment control signal.
Accordingly, the first sheet is set in position on the first tray 310. Subsequently,
the alignment controller 680 generates the alignment control signal whenever the alignment
controller 680 receives the alignment request. Therefore, the cursors 313, 314 reciprocates
in the direction substantially perpendicular to the ejection direction to align the
subsequent sheet with the first sheet so that the lateral edge of the subsequent sheet
overlaps the lateral edge of the first sheet whenever the pulling-back controller
630 outputs the alignment request.
[0146] FIG. 20 is a timing chart of the detection signals from the first and second detectors
611, 612, the drive signal output from the tray controller 660 to the tray driver
324, the stop trigger output from the timer 671 to the tray controller 660, and the
alignment control signal. A relationship among these signals is described with reference
to FIGS. 1, 4, 14, 17, 19 and 20.
[0147] Before the first sheet moves into the detection position (c.f. FIG. 17) of the second
detector 612, the first sheet is moved in the pulling-back direction by the second
ejector 220. Therefore, the second detection signal from the second detector 612 changes
from the low voltage level to the high voltage level with a delay of a given time
period from a time when the first direction signal from the first detector 611 changes
from the high voltage level to the low voltage level (i.e. a time when the first ejector
210 has completed ejection of the first sheet). When the second detection signal from
the second detector 612 is the high voltage, the second detector 612 detects the first
sheet on the first tray 310.
[0148] When the second detection signal from the second detector 612 changes from the low
voltage level to the high voltage level, the alignment controller 680 outputs the
alignment control signal for a given time period so that the cursors 313, 314 come
closer to each other. After an elapse of the given time period, the alignment controller
680 outputs the alignment control signal for a given time period so that the cursors
313, 314 come away from each other. As shown in FIG. 20, before the output of these
alignment control signals are terminated, the stop trigger is output from the timer
671 to the tray controller 660. This means that the downward movement of the second
tray 320 is stopped before the alignment portion 311 completes the positional adjustment
to the first sheet. In short, a time period for the downward movement of the second
tray 320 overlaps a time period required for the alignment portion 311 to adjust the
position of the first sheet. Therefore, it is not necessary to separately set the
time period for the downward movement of the second tray 320.
< Advantageous Effects of Smooth Sheet Conveyance >
[0149] The blower controller 640 makes the first blower 410 blow air over a time period
in synchronization with the first time period from the start to the end of the ejection
of the first sheet to form an airflow between the second tray 320 and the lower surface
of the first sheet when the first sheet is ejected from the first ejector 210. Accordingly,
there is a reduced frictional force between the second tray 320 and the first sheet.
Therefore, the first sheet is conveyed in the pulling-back direction without being
interfered by the frictional force between the second tray 320 and the first sheet,
and smoothly held on the first tray 310.
[0150] The air-blow from the first blower 410 is stopped after the first time period. Therefore,
the frictional force between the second tray 320 and the first sheet increases after
the first time period. Accordingly, the first sheet becomes less likely to be pushed
by the subsequent sheet ejected subsequently to the first sheet.
[0151] The second blower 420 contributes to smooth sheet conveyance as well as the first
blower 410. The second blower 420 blows air to the upper surface region of a sheet
protruding from the second ejector 220 in the ejection direction (i.e. the upper surface
region of a sheet appearing over the second tray 320). Accordingly, the sheet is curved
toward the second tray 320 extending in the ejection direction from a region beneath
the second ejector 220, so that the sheet moves away from an ejection path of the
subsequent sheet. Therefore, a contact area between these sheets is reduced to suppress
a risk of the preceding sheet being pushed by the subsequent sheet.
[0152] When the second blower 420 blows air so that a sheet is curved downwardly, the first
sheet, which is a sheet initially ejected from the first ejector 210 among sheets
in a sheet stack, is pressed against the upper surface of the second tray 320. However,
since the second blower 420 blows air in a smaller volume than the first blower 410,
the first sheet is not pressed against the second tray 320 by an excessively strong
force.
[0153] The tray driver 324 also contributes to a sheet being curved downwardly. Under control
of the tray controller 660, the tray driver 324 moves the second tray 320 downwardly
from the first height position after the first time period. Along with the downward
movement of the second tray 320, the sheet protruding from the first tray 310 toward
the second tray 320 is curved downwardly, so that the sheet moves away from the ejection
path of the subsequent sheet. Accordingly, a contact area between these sheets is
reduced so that there is a decreased risk of the preceding sheet being pushed by the
subsequent sheet.
[0154] The downward movement of the second tray 320 is completed before the alignment portion
311 completes the adjusting operation for adjusting a position of a sheet on the first
tray 310. The downward movement of the second tray 320 is completed within a time
period during which the alignment portion 311 adjusts the position of the sheet on
the first tray 310, so that a time period exclusively used for the downward movement
of the second tray 320 is not required.
[0155] It is determined on the basis of a sheet length in the ejection direction whether
or not the second tray 320 should be moved downwardly. If the sheet length is not
greater than a given length, a preceding sheet is much less likely to be pushed by
a subsequent sheet. Therefore, when the sheet length is not greater than the given
length, the tray controller 660 for controlling the tray driver 324 stays the second
tray 320 at the first height position (the position of the second tray 320 shown in
FIG. 1). Accordingly, electric power for driving the second tray 320 is not wasted.
[0156] Likewise, the blower controller 640 for controlling the first and second blowers
410, 420 makes the first and second blowers 410, 420 blow air on the condition that
the first sheet is longer than the given length. Accordingly, electric power for the
air-blow is not wasted.
[0157] While the first ejector 210 ejects the first sheet, the first blower 410 blows air
under control of the first blower controller 641 to reduce a frictional force between
the lower surface of the first sheet and the second tray 320. After the first sheet
is received in the first tray 310, the airflow for reducing the frictional force between
the lower surface of the first sheet and the second tray 320 becomes unnecessary.
Therefore, the first blower controller 641 stops the air-blow from the first blower
410 when the first sheet is received in the first tray 310. Accordingly, electric
power for the air-blow is not wasted. However, if a large number of subsequent sheets
are stacked on the first sheet, the lower surface of the first sheet may come into
close contact with the upper surface of the second tray 320 due to the weight of the
subsequent sheets. Therefore, after a given number of the subsequent sheets are ejected
from the first ejector 210, the first blower controller 641 restarts the air-blow
from the first blower 410. Accordingly, the first sheet becomes less likely to come
into close contact with the second tray 320, so that a sheet stack formed on the first
tray 310 is smoothly ejected.
[0158] When the sheet stack is formed on the first tray 310, the ejection controller 660
moves the second tray 320 upwardly to the second height position. The second height
position is higher than the first height position before the second tray 320 is moved
downwardly, so that there is a reduced difference in height between the second tray
320 and the second ejector 220. Accordingly, the sheet stack on the first tray 310
is smoothly ejected onto the second tray 320.
[0159] Although the present disclosure has been fully described by way of example with reference
to the accompanying drawings, it is to be understood that various changes and modifications
will be apparent to those skilled in the art. Therefore, unless otherwise such changes
and modifications depart from the scope of the present disclosure hereinafter defined,
they should be construed as being included therein.
1. A post-processing apparatus (100) for performing a given process subsequently to an
image forming process by an image forming apparatus (IFA), comprising:
a first ejector (210) which ejects a first sheet;
a first tray (310) which temporarily holds the first sheet ejected by the first ejector
(210);
a second tray (320) situated downstream of the first tray (310) in an ejection direction
of the first sheet;
a tray driver (324) which moves the second tray (320) downwardly from a first height
position;
a first blower (410) which forms an airstream between the second tray (320) and a
lower surface of the first sheet when the first sheet is ejected by the first ejector
(210); and
a controller (600) which controls the first blower (410) and the tray driver (324),
wherein the controller (600) includes:
(i) a first blower controller (641) which causes the first blower (410) to blow air
over a time period in synchronization with a first time period from a start to an
end of ejection of the first sheet by the first ejector (210); and
(ii) a tray controller (660) which causes the tray driver (324) to move the second
tray (320) downwardly from the first height position after the first time period.
2. The post-processing apparatus (100) according to claim 1,
wherein the controller (600) includes a first detector (611) which detects the first
sheet ejected from the first ejector (210) and generates a detection signal indicative
of the start and the end of the ejection, and
wherein the first blower controller (641) controls the first blower (410) in response
to the detection signal.
3. The post-processing apparatus (100) according to claim 1 or 2,
wherein the tray driver (324) moves the second tray (320) downwardly under control
of the tray controller (660) when the first detector (611) detects the end of the
ejection of the first sheet.
4. The post-processing apparatus (100) according to any one of claims 1 to 3,
wherein the tray controller (660) moves the second tray (320) downwardly from the
first height position if the first sheet is longer in the ejection direction than
a given length, and
wherein the second tray (320) is stayed at the first height position if the first
sheet is not longer in the ejection direction than the given length,
wherein optionally the first blower (410) blows the air under control of the first
blower controller (641) on a condition that the first sheet is longer in the ejection
direction than the given length.
5. The post-processing apparatus (100) according to any one of claims 2 to 4,
wherein the tray controller (660) uses the detection signal to calculate a length
of the first sheet in the ejection direction and compares the calculated length with
a given threshold,
wherein the tray controller (660) moves the second tray (320) downwardly from the
first height position when the calculated length exceeds the given threshold, and
wherein the second tray (320) is stayed at the first height position when the calculated
length is not greater than the given threshold.
6. The post-processing apparatus (100) according to claim 1,
wherein the first ejector (210) sequentially ejects at least one subsequent sheet
subsequently to the first sheet, and
wherein the first tray (310) includes an alignment portion (311) which performs an
aligning operation for aligning the at least one subsequent sheet with the first sheet
so that an edge of the at least one subsequent sheet overlaps an edge of the first
sheet to form a sheet stack, and
wherein the tray controller (660) moves the second tray (320) downwardly before the
alignment portion (311) completes an adjusting operation for adjusting a position
of the first sheet on the first tray (310) in a direction orthogonal to the ejection
direction,
wherein optionally the tray driver (324) moves the second tray (320) upwardly by a
given distance when the first tray (310) holds a second sheet which is the last sheet
ejected from the first ejector (210) in the sheet stack and/or
wherein optionally the second tray (320) moved upwardly by the tray driver (324) reaches
a second height position higher than the first height position.
7. The post-processing apparatus (100) according to claim 6, further comprising:
a second ejector (220) which ejects the sheet stack from the first tray (310) to the
second tray (320); and
a second blower (420) which blows air onto an upper surface of each of the first sheet
and the at least one subsequent sheet when each of them is ejected by the first ejector
(210),
wherein the controller (600) includes a second blower controller (642) which controls
the second blower (420), and
wherein the second tray (320) extends in the ejection direction from a region beneath
the second ejector (220),
wherein optionally the second blower (420) blows less air than the first blower (410).
8. The post-processing apparatus (100) according to claim 7,
wherein the controller (600) includes a first detector (611) which detects the first
sheet ejected from the first ejector (210), and
wherein the first and second blowers (410, 420) start blowing the air under control
of the first and second blower controllers (641, 642) when the first detector (611)
detects the start of the ejection of the first sheet.
9. The post-processing apparatus (100) according to claim 7 or 8, further comprising:
a pulling-back mechanism (500) which moves the at least one subsequent sheet in a
pulling-back direction opposite to the ejection direction to place the at least one
subsequent sheet on the first tray (310),
wherein the controller (600) includes:
a pulling-back controller (630) which controls the pulling-back mechanism (500) to
move the at least one subsequent sheet in the pulling-back direction; and
an alignment controller (680) which controls the aligning operation of the alignment
portion (311),
wherein the alignment controller (680) causes the alignment portion (311) to execute
the aligning operation when the at least one subsequent sheet is moved in the pulling-back
direction under control of the pulling-back controller (630) and placed on the first
tray (310).
10. The post-processing apparatus (100) according to claim 9,
wherein the controller (600) includes a first detector (611) which detects the at
least one subsequent sheet ejected from the first ejector (210) and generates a detection
signal indicative of an end of an ejection of the at least one subsequent sheet, and
wherein the pulling-back controller (630) operates the pulling-back mechanism (500)
for a given time period when the first detector (611) detects the end of the ejection
of the at least one subsequent sheet from the first ejector (210), and
wherein the alignment controller (680) operates the alignment portion (311) after
an elapse of the given time period.
11. The post-processing apparatus (100) according to claim 9 or 10,
wherein the first blower controller (641) stops the first blower (410) in a second
time period during which the pulling-back mechanism (500) conveys the at least one
subsequent sheet in the pulling-back direction.
12. The post-processing apparatus (100) according to one or more of claims 9 to 11,
wherein the first blower controller (641) operates the first blower (410) after the
second time period to restart blowing the air from the first blower (410),
wherein optionally the controller (600) includes:
a first detector (611) which generates a detection signal indicating that a sheet
has passed through the first ejector (210) whenever each of sheets passes through
the first ejector (210); and
a counter (650) which refers to the detection signal to count how many sheets have
passed through the first ejector (210) and compares a resultant count value with a
count threshold, and
wherein the first blower controller (641) causes the first blower (410) to restart
blowing the air on a condition that the count value is coincident with the count threshold.
13. The post-processing apparatus (100) according to any one of claims 9 to 11,
wherein the controller (600) includes: an ejection controller (620) which controls
the second ejector (220); and a first detector (611) which detects the start and the
end of the ejection of the first sheet from the first ejector (210), and
wherein the second ejector (220) sends the first sheet in the ejection direction under
control of the ejection controller (620), and the first and second blowers (410, 420)
start blowing the air under control of the first and second blower controllers (641,
642) when the first detector (611) detects the start of the ejection of the first
sheet; and
wherein the second ejector (220) sends the first sheet in the pulling-back direction
under control of the ejection controller (620) to supply the first sheet onto the
first tray (310), and the first blower (410) stops blowing the air under control of
the first blower controller (641) when the first detector (611) detects the end of
the ejection of the first sheet.
14. The post-processing apparatus (100) according to any one of claims 9 to 11,
wherein the controller (600) includes: an ejection controller (620) which controls
the second ejector (220); a first detector (611) which detects the start and the end
of the ejection of the first sheet from the first ejector (210); and a second detector
(612) which detects the first sheet on the first tray (310), and
wherein the second ejector (220) sends the first sheet in the ejection direction under
control of the ejection controller (620), and the first and second blowers (410, 420)
start blowing the air under control of the first and second blower controllers (641,
642) when the first detector (611) detects the start of the ejection of the first
sheet;
wherein the second ejector (220) sends the first sheet in the pulling-back direction
under control of the ejection controller (620) to supply the first sheet onto the
first tray (310) when the first detector (611) detects the end of the ejection of
the first sheet; and
wherein the first blower (410) stops blowing the air under control of the first blower
controller (641) when the second detector (612) detects the first sheet.
15. The post-processing apparatus (100) according to claim 13 or 14,
wherein the second ejector (220) includes a first roller (221), and a second roller
(222) which is displaceable between an adjacent position adjacent to the first roller
(221) and a distant position distant from the first roller (221), and
wherein the ejection controller (620) places the second roller (222) at the adjacent
position, and bi-directionally rotates the first roller (221) so that the first sheet
is moved in the ejection direction and then in the pulling-back direction when the
first sheet is ejected from the first ejector (210);
wherein the ejection controller (620) places the second roller (222) at the distant
position when the at least one subsequent sheet is ejected from the first ejector
(210); and
wherein the ejection controller (620) rotates the first roller (221) so that the sheet
stack is moved in the ejection direction when the sheet stack is formed on the first
tray (310).